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theres not room to add the humiditrol module downstairs, not enough height available.

the tech is here now. downstairs system is undercharged and not enough wires run to the comfortsense stat to enable dehumidification. this tech is exactly who i needed to come out. he's got a boatload of test equipment, meters, lots of neat stuff with pretty lights and he seems to know how to use all of them.

also he found a 90 degree 'L' and nipple lying loose on top of one of the burner tubes, grounding out the flame sensor in the upstairs furnace.

with big companies it's the luck of the draw with who you get. some good, some worthless. this guy is clean, organized, educated, knows the equipment, he even speaks english. says he'll be here late, until it's all running correctly.

In this situation, would anyone have considered using a single condenser with a variable speed blower and zoning? With humidity issues below, you could easily adjust the dampers so they never fully close, so there will always be air circulating down there even when there is no call.

I wouldn't.
Already set up for 2 units. So by the time you redid the ductwork, and add the zoning system, run larger line set, pull a bigger electrical feed for teh larger outdoor unit. You have about the same cost.
Weather you oversize the lower level with 2 units, or with a zoning system, its still oversized.